A method for reducing the starting time and reducing the peak phase currents for an internal combustion engine that is started using an induction machine starter/alternator. The starting time is reduced by pre-fluxing the induction machine and the peak phase currents are reduced by reducing the flux current command after a predetermined period of time has elapsed and concurrent to the application of the torque current command. The method of the present invention also provides a strategy for anticipating the start command for an internal combustion engine and determines a start strategy based on the start command and the operating state of the internal combustion engine.
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8. A method for determining when to pre-flux an induction machine starter/alternator used for starting an internal combustion engine in a vehicle having a transmission system and a brake system, said method comprising the steps of:
determining a "not running" operating state for the starter/alternator; determining a start status for the internal combustion engine based on said operating state for the starter/alternator; and determining a starting strategy for the induction machine based on said start status for the internal combustion engine.
1. A method for reducing the time to start an internal combustion engine started with an induction machine, said method comprising the steps of:
commanding a flux current alone to the induction machine for a predetermined period of time; and commanding a torque current to the induction machine after said predetermined period of time said flux current alone is commanded to the induction machine; whereby a desired level of torque for starting the internal combustion engine is produced by the induction machine substantially instantaneously when said torque current is commanded to the induction machine.
4. A method for reducing the time to start an internal combustion engine started with an induction machine and for reducing peak current values, said method comprising the steps of:
commanding a flux current alone to the induction machine for a predetermined period of time; and commanding a torque current to the induction machine after said predetermined period of time said flux current alone is commanded to the induction machine; and reducing said commanded flux current when said torque current is commanded; whereby a torque producing current is maximized and a desired level of torque for starting the internal combustion engine is produced by the induction machine substantially instantaneously when said torque current is commanded to the induction machine and the peak current values are minimized.
2. The method as claimed in
3. The method as claimed in
5. The method as claimed in
6. The method as claimed in
7. The method as claimed in
9. The method as claimed in
10. The method as claimed in
receiving an indication that a start command will be sent to the starter/alternator; commanding a flux current to the starter/alternator; holding said flux current constant until said start command is sent; and reducing said flux current when said start command is sent.
11. The method as claimed in
12. The method as claimed in
13. The method as claimed in
14. The method as claimed in
toggling a flux current command between two current values at a frequency related to a predetermined time constant; and reducing said flux current command when a start to engage signal is received within a predetermined time limit.
15. The method as claimed in
toggling a flux current command between two current values at a frequency related to a predetermined time constant; and commanding a constant flux current command in the absence of a start to engage signal being received within a predetermined time limit.
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This invention was made with Government support under Prime Contract No. DE-AC36-83CH10093, Subcontract No. ZCB-4-13032-02, awarded by the Department of Energy. The Government has certain rights in the invention.
The present invention relates generally to an internal combustion engine that is started using an integrated starter/alternator induction machine, and more particularly to a method for reducing the starting time and peak phase currents when starting the internal combustion engine.
High performance torque control of induction machines is based on the concept of field orientation. Field orientation controls the stator currents such that independent control of both the flux and the torque in the machine is achieved. The flux angle used for field orientation can be any one of many fluxes present in the machine. For example, the stator, airgap, or rotor flux. Field orientation based on the rotor flux is the most popular.
There are two different strategies for implementing field orientation. The first, Direct Field Orientation (DFO), orients the control of the stator currents to the flux angle obtained from either a measurement of the flux in an induction machine, or from an estimation of the flux. The second, Indirect Field Orientation (IFO), is based on the slip frequency relationship that must be true in order to align the rotor flux on the direct axis.
In the implementation of either DFO or IFO, the stator current in the rotor flux synchronous reference frame is divided into two components. One component is aligned with the rotor flux vector and the other component is perpendicular to the rotor flux vector. The axis that is aligned with the rotor flux is typically called the direct or d-axis. The axis that is perpendicular to the rotor flux is typically called the quadrature or q-axis.
The overall stator current in the induction machine is related to the d and q-axis stator currents by the relationship:
The component of the stator current along the d-axis is solely responsible for the production of the rotor flux:
The component of the stator current along the q-axis, iqs is proportional to the amount of torque produced:
where:
p=number of poles
λdr=d-axis rotor flux
ids=d-axis stator current
iqs=q-axis stator current
Lm=magnetizing inductance
Lr=rotor inductance
rr=rotor resistance
Equations (1), (2), and (3) show that independent control of both the rotor flux and torque of the machine can be achieved by controlling the d and q-axis stator currents.
Currently known in the art is a brute force starting method in which the flux current command, ids* and the torque current command, iqs* are both applied at the same time the start command for the internal combustion engine is received. The flux current command, ids* is set to a level that results in a desired steady-state rotor flux level, and remains constant throughout the starting event. The torque current command, iqs* is calculated from the flux current command, ids* and the torque command using equation (3) above subject to the overall stator current limit.
There are several disadvantages associated with the brute force starting strategy. First there is a significant delay in the starting response time. The time delay in the starting response is a result of the need to build up the rotor flux in order to produce the desired torque. It is known by equation (2) that there is a low pass filter dynamic on the rotor flux as a function of the flux current command, ids*, with a time constant equal to the rotor time constant, Lr/rr. Therefore, with a constant torque current command, iqs*, the torque also builds up at this rotor time constant.
Another disadvantage is the high peak currents. The high peak currents are a result of commanding a large initial output torque while commanding a large flux current command, ids* to build and maintain the desired rotor flux in the induction machine. During the period of time when the rotor flux is increasing, high stator currents are present in the induction machine in an attempt to produce a large torque. This is in spite of the fact that almost no actual torque is being produced. Therefore, a large percentage of the current, and energy, other than that being used to build the rotor flux, is essentially wasted.
Yet another disadvantage lies in the fact that the high flux current command, ids* is maintained for the duration of the starting event. The result is a further waste of energy. After the initial portion of the start event, little or no torque is required to maintain the engine speed until the engine is started.
In the prior art strategies for starting an internal combustion engine using a starter/alternator induction machine, the peak phase currents are typically very large. Additionally, a delay in the engine start time is caused by starting the engine without any flux in the induction machine and having to wait for the flux to build-up to a sufficient level.
It is an object of the present invention to reduce peak phase currents to reduce the size and cost of the power inverter and not adversely affect the capability of the system. It is another object of the present invention to provide fast response and engine start times by eliminating the delay caused by flux build-up.
It is a further object of the present invention to produce the desired torque as soon as the torque command is received by the system. It is still a further object of the present invention to provide efficient use of the flux energy.
In carrying out the above objects and other objects and features of the present invention, a method is provided for starting an internal combustion engine using a starter/alternator induction machine. i.e. for a hybrid electric vehicle. In the method of the present invention the peak phase currents are minimized, reducing the demand on the power inverter and achieving fast engine start times. According to the method of the present invention, the stator d and q-axis current commands are controlled such that the peak phase currents necessary for starting the internal combustion engine are reduced, while field oriented torque control of the induction machine is maintained, and the torque necessary to provide seamless starting of the engine is produced.
The control method involves pre-fluxing the motor prior to applying the torque command to start the engine. At the time the torque command is applied, the flux command is stepped down to a lower value, allowing the flux to decay to a lower level at a rate equal to the rotor time constant of the induction machine. The control method uses information from vehicle signals and other vehicle subsystems to determine when to perform the pre-flux action.
The method of the present invention is also capable of sensing and determining when a starting event is about to occur. The present invention also provides a strategy for determining the level of starting performance that is required for an impending starting event, as well as how to handle a delayed starting event or a false starting event.
Other objects and advantages of the present invention will become apparent upon reading the following detailed description and appended claims, and upon reference to the accompanying drawings.
For a more complete understanding of this invention, reference should now be had to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention. In the drawings:
The present invention provides several embodiments that adjust the control of both the rotor flux and torque of an induction machine during an engine start, thereby improving the response time and reducing the peak stator phase currents required.
Referring now to
The point at which the "engine starting" event ends is defined as the point at which the starter/alternator reaches a predetermined target speed.
The first embodiment of the present invention is called the pre-flux starting method. According to this embodiment of the present invention, a change in the timing of the application of the current commands, ids* and iqs* is used. In particular, the method involves applying the flux current command, ids* for a predetermined period of time prior to applying the torque current command, iqs*. The flux current command leads the torque current command for a long enough period of time to allow the rotor flux to build-up to an acceptable level.
In another embodiment of the pre-flux starting method described above, the flux current command, ids* is applied before the torque current command, iqs* and is stepped down at the point in time when the torque current command, iqs* is applied. The flux in the rotor is built-up and then the lowered flux current command allows the flux to decay to a lower level at a rate equal to the rotor time constant. Therefore, the flux is initially high enough to produce a large torque, and then decays to a lower level when less torque is necessary. The torque producing current, iqs* is essentially unchanged, but the overall peak phase current is lower since the flux current command component is much smaller.
In yet another embodiment, shown in
The flux reducing methods of the present invention step down the flux command to a level that is much lower than nominal, potentially even zero. This allows the torque producing current to be maximized. The method of the present invention allows a much larger torque to be produced for a smaller current rating since the flux producing current does not need to be applied. The current ratings of the controller electronics can be substantially reduced and still produce the same peak torque. This essentially reduces the overall size and cost of the system.
The lower flux command is possible because the peak torque requirements for the engine start event are very short in duration, i.e. typically less than two rotor time constants. The result is that the decay in the flux level associated with the lower, or zero, flux command does not significantly affect the overall operating system. In fact, the higher peak torque capability at the beginning of the engine start event more than compensates for the reduced capability at the end of the start event.
In a further embodiment, the flux current command, ids* is commanded to a value that is higher than necessary to achieve the desired rotor flux for the pre-flux time period. An initially higher flux current command shortens the amount of time needed for pre-fluxing by building up the rotor flux faster than it would be if the flux current command were based on the desired steady-state rotor flux. As the actual rotor flux approaches the desired level, the flux current command can be decreased to maintain the desired rotor flux until the starting event has occurred. It should be noted that while a higher-than-necessary initial flux current command means faster pre-fluxing, the initial flux current command applied is hardly unlimited. During pre-fluxing, the flux current command is limited by stator current constraints, energy utilization issues, and potentially overheating of the stator windows.
The pre-fluxing of the induction machine can be accomplished by any one of several methods known to one of ordinary skill in the art. The only condition is that the pre-fluxing method used build the flux up to a desired level at a rate as fast as possible. In accomplishing this, the amount of torque produced for the amount of current used is maximized and the amount of time for pre-fluxing is minimized.
To confirm the advantages of the present invention, tests were conducted on a hybrid-electric vehicle having a diesel engine. The tests were performed while starting a warm engine, i.e. >50°C C., whose idle speed was set at 880 RPM. The reference command for the starter/alternator speed control loop was set to 800 RPM. Each of the starting strategies according to the present invention were tested at various maximum torque levels.
It can be determined from
The advantages of the present invention in reducing the engine start time are clearly evident when comparing the time to the first movement of the engine for each of the starting strategies.
It is clear that the pre-flux method with a constant flux current after the starting event provides the best response times for the same current as the brute force method. However, the pre-flux with step down method achieves nearly the same response time, as the constant current method, with about 15% lower peak current for torque limits exceeding 120 Nm. Therefore, when it is desired to reduce starting times and reduce peak current levels, the pre-flux with step down method is the best application.
The performance goals of the starter/alternator starting strategy will change according to the type of start mode. For starts to idle from the key, the goal is to have a starting time less than or equal to three-hundred amps, with peak currents less than or equal to three-hundred amps. The starting time for starts to idle due to low state of charge, or max AC switch engaged are relaxed, while the peak current levels remain at less than or equal to three-hundred msec. Starts to engage from the accelerator pedal need to achieve engine starting times less than or equal to three-hundred msec to ensure the driver receives a responsive feel to throttle commands. It should be noted that these values are for example purposes only.
Referring now to
According to the flowchart 200, the algorithm determines 204 whether or not the VSC is in the driving state (state 3). If this condition is true, then the engine has been running and a start command will result from one of the warm engine restart conditions 206. If the condition 204 is false, this indicates that the next start command will result from a keystart signal 208.
The branch descending from the keystart signal 208 uses the keystart signal from the ignition switch as the indication that the VSC will be sending an engine start command. Once the keystart signal is active 209, the SAM must wait for the pre-charge of the inverter bus to finish and consequently, the main contactor to close 210 before drawing current to pre-flux the induction machine. These conditions are complete when the VSC transitions to the driving state 212. After the VSC transitions to the driving state, there is nominally a 100 to 300 msec delay before the start command is issued. Therefore, assuming the shortest available time delay, the inverter gates are enabled, and a flux current command of 120 amps is applied 214. The flux current command is held constant until the VSC issues the start command 216. At this time, the flux current command is stepped-down 218 to thirty (30) amps and activates the speed control loop to start the engine to the desired idle speed.
If the engine has already been started, the engine starting prediction method becomes much more involved. The branch 206 is used after determining that the engine has been running and will be in a warm engine starting prediction. First the transmission status information is used to determine 220 whether the vehicle is in a "ready-to-drive" condition. If the transmission shift-lever state is in park or neutral, then any start command from the VSC will be a start to idle 222. This condition is not predictive, and therefore, the algorithm resorts to the brute force strategy 224. However, because the performance of this start does not require the response to throttle, it is not as essential, and therefore the torque limit and the flux current command level are reduced to prevent high peak currents.
When the shift lever is detected to be in a position where the vehicle can be launched into motion, the algorithm looks to the state of the brake pedal 226. It is assumed that if the vehicle is in gear, and the driver releases the brake pedal, then the driver intends to press the accelerator to launch the vehicle into motion. Thus, if the brake is off, the SAM begins to pre-flux the machine 228 in an on/off manner, at a frequency related to the rotor time constant.
An example of this pulse-width modulated (pwm) pre-flux process 300 is shown in FIG. 17. In addition to toggling the flux current command between two non-zero values as shown in
Referring back to
The invention covers all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the appended claims.
Degner, Michael W., Amey, David L.
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